Dental appliance having particulate laser marking

ABSTRACT

Dental appliances, materials, and methods of forming such appliances and materials for improved laser marking are provided herein including the use of a particulate material for enhancing laser marking.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.16/562,639, filed Sep. 6, 2019, titled “IMPROVED LASER MARKING OF DENTALAPPLIANCES,” which claims priority to U.S. Provisional PatentApplication No. 62/728,598, filed on Sep. 7, 2018 and entitled “DENTALAPPLIANCES, MATERIALS, AND METHODS OF FORMING SUCH APPLIANCES ANDMATERIALS FOR IMPROVED LASER MARKING,” which is herein incorporated byreference in its entirety.

INCORPORATION BY REFERENCE

All publications and patent applications mentioned in this specificationare herein incorporated by reference in their entirety to the sameextent as if each individual publication or patent application wasspecifically and individually indicated to be incorporated by reference.

TECHNICAL FIELD

The present disclosure is related generally to the field of dentalappliance formation. More particularly, the present disclosure isrelated to dental appliances, materials, and methods of forming suchappliances and materials for improved laser marking.

BACKGROUND

In the dental industry, dental treatments may involve, for instance,restorative and/or orthodontic procedures. Restorative procedures may bedesigned to implant a dental prosthesis (e.g., a crown, bridge inlay,onlay, veneer, etc.) intraorally in a patient. Orthodontic proceduresmay include repositioning misaligned teeth and changing biteconfigurations for improved cosmetic appearance and/or dental function.Orthodontic repositioning can be accomplished, for example, by applyingcontrolled forces to one or more teeth over a period of time.

As an example, orthodontic repositioning may be provided through adental process that uses positioning appliances for realigning teeth.Such appliances may utilize a thin shell of material having resilientproperties, referred to as an “aligner,” that generally conforms to auser's teeth but is slightly out of alignment with a current toothconfiguration. Placement of such an appliance over the teeth may providecontrolled forces in specific locations to gradually move the teeth intoa new configuration. Repetition of this process with successiveappliances in progressive configurations can move the teeth through oneor more intermediate arrangements to a final and/or desired arrangement.

Such systems may utilize materials that are lightweight and/ortransparent to provide as a set of appliances that can be used seriallysuch that, as the teeth move, a new appliance can be implemented tofurther move the teeth.

Specific orthodontic appliances may have to be used in an appropriatesequence and/or be specific to a user. It may be desirable to markaligners with information, patterns, advertising, and/or other items.Existing techniques make it difficult to mark aligners with, e.g.,information, advertising, patterns, etc., particularly in light of thematerial limitations of aligner materials and/or the demands of anintraoral environment.

SUMMARY

Described herein are dental appliances that are configured to allowlaser marking on or within the body of the dental appliance in a highlyenergy-efficient manner, and methods of forming or manufacturing them,including methods of marking them. Any of these variations may include asurface texture that may assist in effectively laser marking the dentalappliance. Alternatively or additionally, any of the dental appliancesmay include an additive material within the aligner body, which may beotherwise transparent and/or translucent, that may react with the laserto enhance marking; for example, the additive may be a particulatematerial having a laser energy absorption characteristic that is greaterthan that of the material used to form the body without the at least oneparticulate material. In some variations the dental appliances includedental aligners or palatal expanders.

Laser marking and mark reading may be part of a dental appliancemanufacturing process. The methods and apparatuses (e.g., systems anddevices, including gin particular dental appliances such as dentalaligners) may save energy and time in the laser marking process byreducing the required laser energy needed to effectively and efficientlymark the material of the dental appliance (e.g., the plastic materialsforming the dental appliance). These methods and apparatuses may alsoallow a high resolution for laser marks and enhance subsequent lasermark reading efficiency.

In some of the variations described herein, one or more additives (e.g.,particulate materials) may be added to the dental appliance throughoutthe entire appliance or restricted to a particular region (orsub-region) to be marked. Such additives may, e.g., utilize nanosecondfiber lasers. Thus, in some variations, an additive material (e.g., aparticulate material) may be included in a center region and/or layer ofthe dental appliance (e.g., a wall of a dental aligner), so that lasermarking may be performed in this region with significantly less laserenergy consumption and faster marking speed than conventionaltechniques. In some variations, the laser marking may be well-defined inthe center of the aligner. Thus, in some variations the surface may beunaffected after laser marking. Laser mark reading efficiency can besignificantly improved because of the resulting high resolution lasermarks with good contrast, sharp edge details.

Any appropriate particulate material that enhances laser marking may beused. For example, the particulate material may be a dye or pigment thathas a laser energy absorption characteristic that enhances marking whenlaser energy is applied. Examples of such particulate materials mayinclude pigments (which may be, for example, suspended within and/orlayered into the material forming a portion of the dental appliance),coatings (e.g., on an inner layer), inks (which may be coated orsuspended within the material forming all or a portion of the dentalappliance) and/or dyes. The particulate material may be a chemicalindicator that irreversibly changes phase based on temperature; heatfrom the applied laser energy may result in a permanent color change.For example, the particulate material may be a heat responsiveirreversible color changing material. In some variations the particulatematerial is a photochromic material that changes color when exposed tocertain wavelengths of light (such as UV light). Examples of particulatematerials may include mica coated with metal oxides (such as seleniumand ferric), pearl pigment, Aluminum silicate, metallic aluminum flakes,iron oxide, etc. For example, a commercially available examples ofparticulate materials that may be used, may include: IRIOTEC 8826(Merck).

In some variations, the dental appliance may include a region having asurface texture that is configured to enhance laser marking. The surfacetexture may be used with or without an additive.

For example, a dental appliance may include a surface of the dentalappliance configured to interface with buccal and lingual regions of apatient, the dental appliance including a plurality of tooth-receivingcavities to receive a corresponding plurality of teeth and to exert oneor more orthodontic repositioning forces on the plurality of teeth, anda first portion of the surface having a first surface texture; a targetmarking area configured to receive a laser mark from a laser; a laseraccess area formed from a second portion of the surface, the laseraccess area configured to provide the laser with access to the targetmarking area, the laser access area having a second surface texturedifferent than the first surface texture, the second surface textureconfiguring the laser access area to disperse laser energy from thelaser when the laser energy is received at the laser access area.

In some variations, a dental appliance may include: an appliance body,at least a portion thereof formed from a material that is transparent tolaser energy to be used to mark the body, wherein; the appliance bodyhas an interior surface to contact surfaces of the one or more teeth andan exterior surface; the appliance body has a target area for lasermarking defined between the interior and exterior surfaces; and theappliance body has a laser access area defined on the a portion of theinterior or exterior surface, wherein the laser access area has arougher surface texture than an adjacent surface.

For example, a dental appliance may include: an appliance body, at leasta portion thereof formed from a material that is transparent to laserenergy used to mark the body; a target area for laser marking on theappliance body between an interior surface and an exterior surface ofthe appliance body; and a laser access area on the exterior surface ofthe appliance body, wherein the exterior surface at the laser accessarea has a rougher surface texture than a region of the exterior surfaceoutside of the laser access area, wherein the rougher surface texture ofthe laser access area is configured to disperse laser energy from alaser beam as the laser beam interacts with the rougher surface texture.

The target marking area may be formed in an intermediate area between anexterior surface and an interior surface of the dental appliance. Insome variations, the target marking area is configured to be near themolars and/or premolars when the device is worn by the patient.

The laser access area may be positioned over all or a portion of thetarget marking area (e.g., may be co-extensive with it) on the surfaceof the dental appliance. The laser access area may be on an interiorsurface of the dental appliance configured to contact the plurality ofteeth and/or on an exterior surface of the dental appliance configuredto face away from the plurality of teeth; the surface may be an outersurface of a transparent body of the dental appliance. For example, thelaser access area may be on one or more of a molar and a premolar regionof the dental appliance.

In general, the laser access area may be surrounded by regions having adifferent surface texture (e.g., a texture that is less roughening thanthe laser access area). In variations having more than one surfacetexture, the second surface texture may be rougher than the firstsurface texture. The laser access area may be a buccal side of thedental appliance.

The rougher surface texture of the laser marking area may be configuredto disperse laser energy as the laser energy interacts with the roughersurface texture. The rougher surface texture of the laser markinglocation may be configured to interact with laser energy to disperse thelaser energy at the target area for laser marking. The rougher surfacetexture of the laser marking location may be configured to interact withlaser energy to disperse the laser energy such that it is absorbed atthe target area for laser marking and none of the laser energy exits theinterior surface. The rougher surface texture may be provided by anon-random pattern of surface features formed in the exterior surface.The rougher surface texture may be provided by a random pattern ofsurface features formed in the exterior surface. The rougher surfacetexture may be provided by a uniform pattern of surface features formedin the exterior surface. The uniform pattern may be configured todisperse laser energy at the target area in a manner based on the laserenergy's interaction with the uniform pattern. The rougher surfacetexture of the laser access area may be configured to disperse laserenergy from a laser beam at the target area. In some variations, thedispersed laser energy at the target area may be configured to promoteheating of material outside of the target area. The dispersed laserenergy at the target area may be configured to promote heating ofmaterial adjacent to the target area.

In any of these apparatuses, the dental appliance may have a body thatis formed of a transparent material; the transparent material may betranslucent.

As mentioned, any of these apparatuses may be configured so that theappliance body includes both a laser marking enhancing surface texture(e.g., the laser access area) on the surface and an inner particulatematter that assists in marking. For example, a dental appliance mayinclude: an appliance body, at least a portion thereof formed from amaterial that is transparent to laser energy used to mark the body; atarget area for laser marking defined between an interior surface and anexterior surface; a laser access area defined on the exterior surface,wherein the exterior surface at the laser access area has a patternedsurface texture formed thereon that is configured to disperse laserenergy from a laser beam within the target area; and a particulatematerial within the target area, the particulate material having laserenergy absorption characteristics that are greater than that of thematerial forming the appliance body without the particulate material.

The particulate material may not be present within a region of theappliance body adjacent to the target area. The patterned surfacetexture may be any of those described above. As mentioned, theparticulate material comprises a pigment or dye.

Also described herein are methods, including methods of forming any ofthe apparatuses described herein and/or methods of marking any of theseapparatuses. For example, a method may include: forming, as part of adental appliance (e.g., aligner) a target marking area configured toreceive a laser mark from a laser; forming a laser access area on aportion of the surface of the dental appliance, wherein the laser accessarea is configured to provide the laser with access to the targetmarking area; the portion of the surface forming the laser access areamay be formed of a first polymeric material having a first surfacetexture; other surface regions of the dental appliance may be formedhaving a second surface texture that is different than the first surfacetexture, the first surface texture may configure the laser access areato disperse laser energy from the laser when the laser energy isreceived at the laser access area.

In some variations, a method may include identifying a surface of adental appliance, the surface having a first portion configured tointerface with buccal and lingual regions of a patient, the surfaceincluding a plurality of tooth-receiving cavities to receive acorresponding plurality of teeth and to exert one or more orthodonticrepositioning forces on the plurality of teeth; identifying a targetmarking area configured to receive a laser mark from a laser;identifying a laser access area to be formed on a second portion of thesurface, the laser access area configured to provide the laser withaccess to the target marking area; forming the first portion of thesurface with a first polymeric material having a first surface texture;forming the second portion of the surface with a second polymericmaterial, the second polymeric material having a second surface texturedifferent than the first surface texture, the second surface textureconfiguring the laser access area to disperse laser energy from thelaser when the laser energy is received at the laser access area.

For example, a method of forming a dental appliance may include: formingan appliance body from at least one material, at least a portion of thebody being transparent to laser energy, and wherein the body is formedsuch that a target area for laser marking is defined between an interiorsurface and an exterior surface of the appliance body; defining a laseraccess area on at least one of the interior or exterior surface; androughing the laser access area such to have a rougher surface texturethan at least one of, a portion of the exterior surface that is notwithin the laser access area or a portion of the interior surface.

Any of these methods may be processes for forming a dental appliance,and may include, for example: forming an appliance body from at leastone transparent material, at least a portion of the body beingtransparent to laser energy, and wherein the body is formed such that atarget area for laser marking is defined between an interior surface andan exterior surface of the appliance body; and applying a roughingmaterial to at least one of the interior surface and the exteriorsurface to rough at least a portion of the at least one surface.Alternatively or additionally to including roughening the surface (e.g.,to form a laser access region) the method may include adding aparticulate material (as described herein) in an intermediate region tobe marked.

For example, a method may include: forming, as part of a dentalappliance (e.g., a dental aligner), a target marking area on the dentalappliance, the target marking area residing in an intermediate arearesiding between the exterior surface and the interior surface of thebody of the dental appliance, wherein the body has a first laserabsorption characteristic and the target marking area may be formed froma second region of polymeric material comprising a particulate matterinterspersed with a polymeric material, so that the second region has asecond laser absorption characteristic that is greater than the firstlaser absorption characteristic.

For example, a method may include: identifying an exterior surface of adental appliance, the exterior surface configured to interface withbuccal and lingual regions of a patient; identifying an interior surfaceof the dental appliance, the interior surface including a plurality oftooth-receiving cavities to receive a corresponding plurality of teethand to exert one or more orthodontic repositioning forces on theplurality of teeth; identifying a target marking area on the dentalappliance, the target marking area residing in an intermediate arearesiding between the exterior surface and the interior surface; formingthe interior surface and the exterior surface from a first polymericmaterial, the first polymeric material having a first laser absorptioncharacteristic; forming the laser access area from a second polymericmaterial comprising interspersed particulate matter interspersed withthe first polymeric material, the second polymeric material having asecond laser absorption characteristic greater than the first laserabsorption characteristic.

The step of roughing at least a portion of the laser access area mayinclude applying a chemical material to the laser access surface thatinteracts with the material forming the body to create the roughersurface texture. The step of roughing at least a portion of the laseraccess area may include applying an abrasive material against the laseraccess surface that interacts with the material forming the body tocreate the rougher surface texture. In some variations, roughing atleast a portion of the laser access area includes applying a patternedshape against the laser access surface that interacts with the materialforming the body to create the rougher surface texture. In somevariations, roughing at least a portion of the laser access areaincludes applying a random shape against the laser access surface thatinteracts with the material forming the body to create the roughersurface texture. In some variations, roughing at least a portion of thelaser access area includes applying a shaped material against the laseraccess surface that interacts with the material forming the body tocreate the rougher surface texture and wherein the method furtherincludes heating the material forming the body to conform the exteriorsurface to a shape of a surface of the shaped material.

In some variations, the roughing material is a chemical material thatinteracts with the transparent material (e.g., the material forming thedevice body) to rough at least one of the interior surface and theexterior surface. The roughing material may be an abrasive material thatinteracts with the transparent material to rough at least one of theinterior surface and the exterior surface. The roughing material may bea patterned form that interacts with the transparent material to roughat least one of the interior surface and the exterior surface.

Any of these methods may include forming an appliance body bythermoforming the appliance body from a sheet of material placed over amold of a patient's teeth based on an arrangement of the teethdetermined by a treatment plan. In some variations, forming an appliancebody includes printing the appliance body based on an arrangement of theteeth determined by a treatment plan.

Also described herein are apparatuses (and methods of forming and/ormarking them) that include a material (e.g., a particulate material)that is included within the body of at least a region of the dentalapparatus to enhance marking. In some variations this particulatematerial may be disbursed within the marking region between the innerand outer surfaces of the dental apparatus. In some variations theparticulate material is distributed or concentrated within a layer orinner region of the marking region. As mentioned above, these devicesmay include or not include a surface texture for enhancing lasermarking.

For example, described herein are dental appliances, comprising: anappliance body formed from at least one material and at least a portionof the body being transparent to laser energy, wherein; the body havingan interior surface to contact surfaces of the one or more teeth and anexterior surface, and a first target area for laser marking within thebody between the interior and exterior surfaces; and the first targetarea within the body contains a quantity of at least one particulatematerial interspersed within the first target area, the at least oneparticulate material having laser energy absorption characteristics thatare greater than that of the material used to form the body without theat least one particulate material.

For example, a dental appliance may include: an appliance body formedfrom at least one material wherein at least a portion of the body istransparent to laser energy, wherein; an interior surface on theappliance body configured to contact surfaces of the one or more teethand an exterior surface, and a first target area of the appliance bodyfor laser marking within the body between the interior and exteriorsurfaces; and a means for increasing one or more laser energy absorptioncharacteristics that are present in the at least one material that istransparent to laser energy.

A dental appliance may include: an exterior surface formed from a firstpolymeric material, the first polymeric material having a first laserabsorption characteristic, the exterior surface configured to interfacewith buccal and lingual regions of a patient; an interior surface formedfrom the first polymeric material, the interior surface including aplurality of tooth-receiving cavities to receive a correspondingplurality of teeth and to exert one or more orthodontic repositioningforces on the plurality of teeth; an intermediate area residing betweenthe exterior surface and the interior surface, the intermediate areaincluding a target marking area formed from a second polymeric materialcomprising interspersed particulate matter interspersed with the firstpolymeric material, the second polymeric material having a second laserabsorption characteristic greater than the first laser absorptioncharacteristic.

For example, a dental appliance may include: an appliance body, at leasta portion thereof being transparent to laser energy used by a laser thatdirects laser energy at the appliance body to conduct laser marking andthe body having a plurality of cavities therein designed to receive oneor more teeth of a jaw of a patient and the plurality of cavitiesproviding force to reposition at least one tooth of the jaw with respectto at least one other tooth of the jaw, wherein; the body has aninterior surface to contact surfaces of the one or more teeth and anexterior surface; and the body is formed such that a first target areafor laser marking is defined within the body between the interior andexterior surfaces; and the first target area within the body contains afirst quantity of a first particulate material interspersed within thefirst target area, the first particulate material having laser energyabsorption characteristics that are greater than that of materialforming portions of the body outside of the first target area.

As mentioned, the particulate material may comprise a pigment or dye. Aquantity of first particulate material may be interspersed within thematerials forming the entire body; alternatively, the first particulatematerial may be restricted to a region to be marked (including assub-region, such as within an internal layer).

The material of the body may be formed such that a second target areafor laser marking is defined within the body between the interior andexterior surfaces, and the second target area within the body maycontain a quantity of second particulate material interspersed withinthe second target area. The body may be formed from multiple layers andthe first target area may be within a first layer and wherein materialof the body is formed such that a second target area for laser markingis defined within a second layer of the body between the interior andexterior surfaces, and the second target area within the body maycontain a quantity of second particulate material interspersed withinthe second target area.

The first target area within the body may contains a quantity of asecond particulate material interspersed within the first target area.The first particulate material may have a heightened reactivity to afirst range of wavelengths of laser energy as compared to a second rangeof wavelengths. The second particulate material may have a heightenedreactivity to a second range of wavelengths of laser energy that is adifferent range of wavelengths than the first range of wavelengths.

In any of these dental appliances, the dental appliance may be one of aseries of removable polymeric orthodontic appliances. The interspersedparticulate matter may comprise one or more of an additive, a filler, apigment, and a dye. The first quantity of first particulate material maybe interspersed within the first target area and a second quantity ofthe at least one particulate material may be interspersed in a portionof the material of the body that is outside the first target area. Thefirst target area within the body of the dental appliance may contain aquantity of a second particulate material interspersed within the firsttarget area. The second particulate material may have a differentaverage particle size than the first particulate material. The secondparticulate material may have a different average particle density as itis dispersed throughout the body than the first particulate material.

BRIEF DESCRIPTION OF THE DRAWINGS

Novel features of embodiments described herein are set forth withparticularity in the appended claims. A better understanding of thefeatures and advantages of the embodiments may be obtained by referenceto the following detailed description that sets forth illustrativeembodiments and the accompanying drawings.

FIG. 1 illustrates a perspective view of a dental appliance according toone or more embodiments of the present disclosure.

FIG. 2A illustrates a method for forming a dental appliance according toa number of embodiments of the present disclosure.

FIG. 2B illustrates a method for forming a dental appliance according tosome implementations.

FIG. 2C illustrates a method for forming a dental appliance according tosome implementations.

FIG. 2D illustrates a method for forming a dental appliance according tosome implementations.

FIG. 3 illustrates another perspective view of a dental applianceaccording to one or more embodiments of the present disclosure.

FIGS. 4A-4H illustrate a number of target areas defined within a dentalappliance according to a number of embodiments of the presentdisclosure.

FIGS. 5A and 5B illustrates a method for forming a dental applianceaccording to a number of embodiments of the present disclosure.

FIG. 6 illustrates a computing system for use in a number of embodimentsof the present disclosure.

FIG. 7 illustrates a computing system for use in a number of embodimentsof the present disclosure.

FIG. 8 illustrates a non-transitory computer readable medium havinginstructions for forming a dental appliance according to a number ofembodiments of the present disclosure.

FIG. 9 illustrates a non-transitory computer readable medium havinginstructions for forming a dental appliance according to a number ofembodiments of the present disclosure.

FIG. 10A illustrates a method for providing a laser mark through a laseraccess area of a dental appliance, according to some implementations.

FIG. 10B illustrates a method for providing a laser mark to a targetmarking area of a dental appliance, according to some implementations.

FIG. 11 illustrates one example of laser marking on a substrate (e.g.,Tridan 30) having different surface textures (first textured side onleft, and second textured side on right).

FIG. 12 illustrates one example of laser marking on a substrate (e.g.,ST 30) having different surface textures (first textured side on left,and second textured side on right).

FIG. 13 illustrates one example of laser marking on a substrate (e.g.,EX 30) having different surface textures (first textured side on left,and second textured side on right).

DETAILED DESCRIPTION

Existing techniques make it difficult to mark dental appliances, such asorthodontic aligners with marks. This may be due to various reasons,including the limitations of aligner materials and the rigorous demandsof an intraoral cavity. Various implementations feature a dentalappliance (e.g., an orthodontic aligner), at least a portion of which isformed from materials that facilitate improved laser marking. As notedherein, a laser mark on a dental appliance formed according to variousimplementations may withstand the humidity, temperature, and otherdemands of an intraoral environment. The laser mark may be formed by“laser energy,” which as used herein, may include any light (e.g.,visible, non-visible, etc.) and/or laser. Laser energy need not bevisible light.

FIG. 1 shows an example of a dental appliance 100, according to someimplementations. The dental appliance 100 includes an interior surface102 and an exterior surface 104. The interior surface 102 may be acavity-receiving surface of the dental appliance 100 and may include aplurality of tooth-receiving cavities to receive teeth of a dentition ofa patient and exert repositioning forces thereto. The exterior surface104 may comprise a buccal and/or lingual surface of the dental appliance100.

The dental appliance 100 may include an appliance body (not labeled inFIG. 1). The dental appliance 100 may include a laser access area 106and a target marking area 108. In this example of FIG. 1, the laseraccess area 106 is formed on the body of the appliance, shown in FIG. 1as formed from the exterior surface 104. However, it is noted that suchan illustration is by way of example only, and in variousimplementations, the laser access area 106 may be formed on the interiorsurface 102 of the dental appliance 100.

The laser access area 106 in FIG. 1, and any “laser access area” as usedherein, may include a physical region of the dental appliance 100 thatallows a laser or other light energy to access a part of the dentalappliance 100 in order to mark the dental appliance 100. The laseraccess area 106 may have a surface texture that is different than thesurface texture of another area of the dental appliance 100. “Surfacetexture,” as used herein, may include a property of a surfacecharacterized by lay, surface roughness, waviness, or some combinationthereof. Surface texture may comprise small and/or local deviations of asurface from an ideal plane or flat surface. Surface roughness mayinclude deviations in a direction of a normal vector from the normalvectors of an ideal plane or flat surface. Large deviations maycorrespond to a “rougher” surface (of greater surface roughness) whilesmaller deviations may correspond to a “smoother surface” (of lessersurface roughness). Waviness may include deviations due to, e.g.,machine or work deflections, chatter, residual stress, vibrations,and/or heat treatment. As an example of different surface textures, thelaser access area 106 may have a surface roughness that is greater thana surface roughness of other parts of the dental appliance 100. Thesurface texture of the laser access area 106 may be characterized by alarger number of deviations in the direction of normal vector(s) fromits surface than the number of deviations in the direction of the normalvector from the surface of other areas of the dental appliance 100. Insome implementations, the surface roughness of the laser access area 106may be greater than the surface roughness of surrounding and/or otherareas of the exterior surface 104. The surface roughness of the laseraccess area 106 may also be greater than the surface roughness ofportions of the interior surface 102.

A laser access area may be on a buccal side or a lingual side and may belimited to a region over the premolar and/or molars. In some variations,it may be beneficial for a laser access region to be on the buccal sidenear the molar and/or premolar region.

The laser access area 106 may be configured to disperse laser energyprovided to it. Dispersal of laser energy through the laser access area106 (e.g., through the higher surface roughness of the laser accessarea) may allow the laser energy to be better absorbed at the targetmarking area 108 than it would were the laser access area 106 had alower surface roughness. This may prevent a significant portion of thelaser energy from exiting the target marking area 108 and/or may reducedamage to the target marking area 108. The rougher surface texture ofthe laser marking area 106 may also reduce damage or unintended marks onthe target marking area 108.

In some embodiments, the rougher surface texture can be provided by anon-random (e.g., uniform) pattern of surface features formed in theexterior surface 104 and/or the interior surface 102. The non-randompattern of surface features can be configured to disperse laser energyat the target marking area 108 in a manner based on the laser energy'sinteraction with the non-random pattern. As used herein, a non-randompattern can include a pattern that conforms to one or more deterministicrelationships (repeating patterns, organized patterns, patterns that canbe modeled by parametric functions, etc.). A random pattern as usedherein can include patterns that do not conform to deterministicrelationships (e.g., are non-repeating, have surface features that arenot deterministically placed with respect to each other, etc.).

In some embodiments, a rougher surface area can be provided by a randompattern of surface features formed in the exterior surface 104 or theinterior surface 102. A random pattern of surface features can beconfigured to disperse laser energy at the target marking area 108 in amanner based on the laser energy's interaction with the random pattern.

Surface features formed in the exterior surface 104 and/or the interiorsurface 102 of the dental appliance 100 can include height variations,translucency variations, and density variations, among other surfacefeatures. The term “translucent,” as used herein, may include a propertyof a material that allows light energy to pass through. A translucentmaterial may also be “transparent,” which, as used herein, may include aproperty of material that allows light energy to pass through so thatobjects behind the material can be seen.

The surface features can be configured to promote heating in one or moreparticular areas of the target marking area 108 when the laser energy isapplied to the dental appliance 100 by the laser marking source. Theparticular areas of the target marking area 108 that are heated when thelaser energy is applied can be the areas within the target marking area108 that are laser marked. Additionally, the dispersed laser energy atthe target marking area 108 can be configured to promote heating ofmaterial outside of and/or adjacent to the target marking area 108 inaddition to within the target area, in some embodiments. In someembodiments, the laser access area may be sensitized to the laser energy(e.g., by the surface features or otherwise, as described herein) ascompared to other regions of the aligner outside of the laser accessarea, for visibly marking by the laser.

In some implementations, the laser access area 106 can be defined on theinterior surface 102 or the exterior surface 104. In theseimplementations, the laser access area 106 may align with the targetmarking area 108, and the target marking area 108 may be defined betweenthe interior surface 102 and the exterior surface 104 of the dentalappliance 100. Such alignment may cause laser energy to pass through thelaser access area 106 before the laser energy enters the target markingarea 108. In various embodiments, the laser access area 106 can bedefined on the interior surface 102 of the dental appliance 100. Asnoted herein, an example interior laser access area can have a roughersurface texture than the portions of the appliance that are outside ofthe interior laser access area.

The target marking area 108 and any “target marking area” as usedherein, may include a physical region configured to receive and/or bemarked with a laser mark. The target marking area 108 may be formed inan intermediate area 110 of the dental appliance 100. The intermediatearea 110 may comprise a portion of a body of the dental appliance 100and may reside between the interior surface 102 and the exterior surface104. In various implementations, the target marking area 108 may havelaser radiation absorption characteristics that are greater the laserradiation absorption characteristics of other portions of the dentalappliance 100. A “laser radiation absorption characteristic,” as usedherein, may include the ability of that material to absorb photons oflaser radiation. A laser radiation absorption characteristic of amaterial may, but need not, relate to the relative transparency of thematerial in relation to laser radiation. Laser radiation absorptioncharacteristics of material may relate to the ability of the material tointeract with photons of laser radiation, e.g., at the atomic level.Laser radiation absorption characteristics of a material may relate tothe ability of the material to transform photons of laser radiation tointernal energy, e.g., thermal energy, within the material. In someimplementations, materials with higher laser radiation absorptioncharacteristics may attenuate photons of laser radiation more greatlythan materials with lower laser radiation absorption characteristics. Itis noted laser radiation absorption may relate to linear absorption,non-linear absorption, and/or absorption characterized by otherfunctions of photons. Additionally, while FIG. 1 shows the targetmarking area 108 formed in the intermediate area 110, in variousimplementations, the target marking area 108 may be formed in theinterior surface 102, the exterior surface 104, the intermediate area110, and/or any combination thereof.

In some implementations, the target marking area 108 may be formed froma substantially transparent and/or translucent material. It is noted“transparent,” “translucent,” and/or other optical properties of amaterial may be defined relative to a light source. E.g., a material maybe “transparent,” or “translucent” to non-visible light but may still beopaque to visible light. In some embodiments, the target marking area108 may be formed from a light transmissive material to allow light froma laser marking source to it. The target marking area 108 for lasermarking can be defined between the interior surface 102 and an exteriorsurface 104 of the dental appliance 100. The target marking area 108 forlaser marking can be the laser marking location within the dentalappliance 100 where the laser marking will appear.

In some implementations, the target marking area 108 can containparticulate material with laser radiation absorption characteristicsthat are greater than the laser radiation absorption characteristics ofother portions of the dental appliance 100. “Particulate matter,” asused herein, may include solid and/or liquid matter (e.g., microscopicsolid and/or liquid matter) interspersed in dental appliance material(e.g., interspersed in the polymeric materials of the dental appliance).Examples of particulate matter include, e.g., additives, fillers,pigments, and dyes that enhance the absorption of laser energy forlocalized color changes.

In some implementations, laser radiation absorption characteristics ofthe target marking area 108 may be greater than laser radiationabsorption characteristics of substantially transparent material(s) usedto form the dental appliance 100. The laser radiation absorptioncharacteristics of the target marking area 108 may allow for increasedmarking quality, including increased marking contrast, line edgeddetail, and/or marking speed on the dental appliance 100.

The dental appliance 100 may interact with laser radiation and/or otherforms of radiation in order to accurate laser marks on appliance 100and/or laser marks that do not damage portions of the dental appliance100. As noted herein, the dental appliance 100 may interact with laserradiation and/or other forms of radiation in order to accurately receivelaser marks on appliance 100 and/or laser marks that do not damageportions of the dental appliance 100. The relatively rough surfacetexture of the laser access area 106 (e.g., relative to other portionsof the dental appliance 100) may cause laser energy directed to it todisperse. Such dispersal may cause the laser energy to be moreefficiently absorbed by the target marking area 108 so that very littleof the laser energy exits (e.g., is reflected from) the target markingarea 108. In an example implementation where the laser access area 106is defined on an exterior surface 104 of the appliance 102, the laseraccess area 106 can have a rougher surface texture than at least oneother portion of the appliance that is outside of the exterior laseraccess area 106. Directing light from the laser marking source at theexterior laser access area 104 with the rougher surface texture candisperse the laser energy from the light such that it is absorbed at thetarget marking area 108 for laser marking and little or none of thelaser energy exits the interior surface 102 of the dental appliance 100.As an example, directing light from the laser marking source at theexterior laser access area 104 with the rougher surface texture candisperse the laser energy from the light such that it is absorbed at thetarget marking area 108 for laser marking and less than a thresholdamount of laser energy (e.g., less than a specific number of Watts (W)of laser energy) exits the interior surface 102 of the dental appliance100. In some embodiments, the laser energy can be reduced or in som0065cases fully absorbed at the target marking area 108, eliminating excesslaser energy which can damage the portions of the dental appliance 100outside of the target marking area 108 and improve the quality of thelaser marking.

The technology of the described implementations may make it easier tocorrectly sequence orthodontic aligners during various phases, includingproduction and/or application of orthodontic aligners to treat patients.Use of laser marks on the dental appliance 100 may allow an appropriatedental appliance to be used in the correct sequence and/or is specificto a particular user. Laser marking may be used to mark the dentalappliance 100 with a label, (a numerical number, an alphanumericsequence, design, etc.), to indicate the sequence that the dentalappliance 100 is implemented. Markings can also include patient readableinformation, such as a patient ID and stage, among other information. Insome embodiments, such information can be used during manufacture tokeep the appliances in the correct order or to keep a set of appliancestogether, in preparation for shipping to the patient or treatmentprofessional.

It is noted the dental appliance 100 may represent one of a plurality ofincremental dental position adjustment appliances. The dental positionadjustment appliances can be utilized to incrementally implement atreatment plan for the movement of teeth on the jaws of the patient suchas by affecting incremental repositioning of individual teeth in a jawon which the appliance is placed, among other suitable uses. The dentalposition adjustment appliances can be fabricated according to a virtualdental model that has had positions of a number of teeth adjusted fromtheir current position in a patient's mouth, to allow the teeth to moveto the adjusted positions.

The dental appliance 100 may, but need not, be fabricated from apolymeric shell, and/or formed from other material, having a pluralityof cavities therein. The cavities can be designed (e.g., shaped) toreceive one or more teeth and/or apply force to reposition one or moreteeth of a jaw from one teeth arrangement to a successive teetharrangement. The shell may be designed to fit over a number of, or inmany instances all, teeth present in the upper and/or lower jaw. Theshell can include an interior surface 102 (e.g., adjacent to a surfaceof the teeth placed therein) to contact surfaces of one or more teethand an exterior surface 104.

In some implementations, the dental appliance 100 need not be a toothrepositioning appliance. The dental appliance 100 may include anypositioners, retainers, restorative appliances, and/or other removableappliances for finishing and maintaining teeth positioning or provideother functionalities to a patient, such as aiding in sleep apnea orbruxism, in connection with a dental treatment. These appliances may beutilized by a treatment professional in performing a treatment plan. Forexample, a treatment plan can include the use of a set of appliances,created according to models described herein.

FIG. 2A illustrates a flowchart of a method 200A for forming a dentalappliance according to some implementations. The method 200A may includemore or less operations than those explicitly shown in FIG. 2A. Some orall of the operations of the method 200A may be executed by thecomputing system 650 and/or other structures shown in FIG. 6. The method200A may be used for forming the dental appliance 100 shown in FIG. 1.

At an operation 212, forming the dental appliance can include forming anappliance body from at least one material, at least a portion of thebody being transparent to laser energy. As previously described, theappliance can be fabricated from a polymeric shell, and/or formed fromother material, having a plurality of cavities therein.

The cavities can be designed (e.g., shaped) to receive one or more teethand/or apply force to reposition one or more teeth of a jaw from oneteeth arrangement to a successive teeth arrangement. The shell may bedesigned to fit over a number of, or in many instances all, teethpresent in the upper and/or lower jaw. The shell can include an interiorsurface (e.g., adjacent to a surface of the teeth placed therein) tocontact surfaces of one or more teeth and an exterior surface.

In an embodiment, the appliance body can be fabricated from atransparent (e.g., translucent) material for improved laser marking. Insome embodiments, the dental appliance 102 may be formed from a lighttransmissive material to allow light (e.g., a laser beam) from the lightsource to mark the transparent material of the dental appliance 102.However, in some embodiments, the light used to mark the dentalappliance 102 may not be visible light and, in such embodiments, thematerial may be transparent to the type of non-visible light that isbeing used for marking the dental appliance (e.g., ultraviolet (UV)light, infrared light, etc.).

Further, the body of the appliance can be formed such that a target areafor laser marking is defined between an interior surface and an exteriorsurface of the appliance body. The target area for laser marking can bethe laser marking location within the appliance. The laser marking caninclude objects imprinted (e.g., marked) into the material of theappliance, such as appliance and/or patient identification informationor decorative marking, such as brand logos or object (e.g., a flowerdesign) selected by a patient.

Laser energy can be dispersed at the target area to promote modification(e.g., by heating) of the material resulting in the imprinting of theobject into the appliance. In some embodiments, the laser marking (e.g.,the imprinted object) can be colored, as will be discussed in moredetail below.

In some embodiments, as described herein, at least a portion of the areabetween the interior and exterior surface can include a quantity ofparticulate material that is configured to absorb the light energy thatinteracts with the textured surface and directed to the portion of thearea between the interior and exterior surface. By absorbing the laserenergy, the particulate material can help form a higher quality lasermaser mark than would be defined within the appliance if there wasexcess laser energy. The (e.g., roughened) surface texture and/or theparticulate interspersed within the target area of the appliance can, insome embodiments, allow for portions outside of the target area and thelaser access area to remain unaffected (e.g., smooth) after lasermarking. Additionally or alternatively, directing and absorbing thelight energy at the target area can result in laser markings with highcontrast and sharp edge details. Thus, the reading efficiency of thelaser marking can be improved.

At an operation 214, forming the dental appliance can further includedefining a laser access area on at least one of the interior or exteriorsurface. The laser access area can be defined on an interior surface oran exterior surface that aligns with the target area defined between theinterior surface and the exterior surface of the appliance allowing thelaser energy of the light from a laser marking source to be dispersed atthe target area for laser marking.

At an operation 216, forming the dental appliance can further includeroughing at least a portion of the laser access area such that theroughed portion has a rougher surface texture than at least one of, aportion of the exterior surface that is not within the laser access areaor a portion of the interior surface. Roughing can, for example, be theapplication of a number of surface features to an exterior portion ofthe appliance causing the roughed (e.g. not smooth) exterior portion ofthe appliance to have a rougher surface texture than at least one of, aportion of the virtual exterior surface that is not within the laseraccess area or a portion of the virtual interior surface where roughinghas not occurred.

Roughing at least a portion of the laser access area can includeapplying a roughing material to at least a portion of the laser accessarea on the interior surface or the exterior surface of the appliance.For example, roughing at least a portion of the laser access area caninclude applying a chemical material to the laser access surface thatinteracts with the material (e.g., a transparent material) forming thebody of the appliance to create the rougher surface texture, applying anabrasive material (e.g., sand paper, a bur tool, etc.) against the laseraccess surface that interacts with the material forming the body of theappliance to create the rougher surface texture, applying a patternedshape (e.g., an embossing stamp with the shaped formed thereon) againstthe laser access surface, applying a random shape against the lasersurface that interacts with the material forming the body of theappliance to create the rougher surface texture, and applying a shapedmaterial against the laser access surface that interacts with thematerial forming the body of the appliance to create the rougher surfacetexture, among other methods of creating the rougher surface texture.Applying the shaped material against the laser access surface thatinteracts with the material forming the body of the appliance to createthe rougher surface texture can also include heating the materialforming the body to aid in conforming the exterior surface to a shape ofa surface of the shaped material applied to the exterior surface.

Texturing (e.g., roughing) at least a portion of the laser access areacan result in surface features (e.g., height variations, translucencyvariations, density variations, etc.) which can promote heating in oneor more particular areas of the target area when the laser energy isapplied to the appliance. Additionally, texturing (e.g., by roughening)at least a portion of the laser access can allow the surface features ofthe textured portion of the appliance to disperse the laser energy atthe target area in a manner based on the laser energy's interaction withthe surface features of the roughed portion of the appliance. The laserenergy can be dispersed such that it is absorbed at the target area andnone of the laser energy exits an exterior surface of the appliance.

FIG. 2B illustrates a flowchart of a method 200B for forming a dentalappliance according to some implementations. The method 200B may includemore or less operations than those explicitly shown in FIG. 2B. Some orall of the operations of the method 200B may be executed by thecomputing system 650 and/or other structures shown in FIG. 6. The method200B may be used for forming the dental appliance 100 shown in FIG. 1.

At an operation 221, a target marking area on a dental appliance formarking the dental appliance with a laser mark may be identified. As anexample, the target marking area 108 on the dental appliance 100 may beidentified. In various implementations, the target marking area isidentified on a computer system either with an automated agent or anindividual identifying a virtual representation of the target markingarea. The target marking area may also be identified by a machine or anindividual identifying an area of a dental appliance. The target markingarea may comprise a portion of an intermediate area, an interior area,an exterior area, or some combination thereof of the dental appliance100. The target marking area may include a laser mark. The laser markmay represent, e.g., appliance and/or patient identificationinformation, decorative marking, brand logos, designs, patient-selectedinformation/decorations, etc.

At an operation 223, a laser access area on the dental appliance thatcorresponds to a region of the dental appliance that provides laseraccess to the target marking area may be identified. To continue theforegoing example, the laser access area 106 on the dental appliance 100may be identified. The laser access area may be identified on a computersystem either with an automated agent or an individual identifying avirtual representation of the laser access area. The laser access areamay also be identified by a machine or an individual identifying an areaof a dental appliance. The laser access area may comprise a portion ofan interior area or an exterior area of the dental appliance thatresides proximate to the target marking area.

At an operation 225, a surface texture of the laser access area may beformed to disperse laser energy provided to the laser access area. Thelaser access area may comprise an area having a surface texturedifferent (e.g., rougher) than the surface texture of other portions ofthe dental appliance, such as areas of the dental appliance surroundingand/or proximate to the laser access area. A machine or a human operatormay achieve the different surface texture by abrading, roughing, etc.the surface of the laser access area relative to other areas of thedental appliance. A machine or a human operator may achieve thedifferent surface texture by including an affirmative manufacturing stepto form the laser access area from a different (e.g., rougher) materialthan other areas of the dental appliance so that the laser access areacauses laser energy to disperse through it. Forming the laser accessarea may include using thermoforming techniques over a physical mold(e.g., a 3D printed mold) and/or direct fabricating/3D printing thelaser access area to have a differing surface texture than other areasof the dental appliance.

FIG. 2C illustrates a flowchart of a method 200C for forming a dentalappliance according to some implementations. The method 200C may includemore or less operations than those explicitly shown in FIG. 2C. Some orall of the operations of the method 200C may be executed by thecomputing system 650 and/or other structures shown in FIG. 6. The method200C may be used for forming the dental appliance 100 shown in FIG. 1.

At an operation 227, a target marking area on a dental appliance formarking the dental appliance with a laser mark may be identified. As anexample, the target marking area 108 on the dental appliance 100 may beidentified. In various implementations, the target marking area isidentified on a computer system either with an automated agent or anindividual identifying a virtual representation of the target markingarea. The target marking area may also be identified by a machine or anindividual identifying an area of a dental appliance. The target markingarea may comprise a portion of an intermediate area, an interior area,an exterior area, or some combination thereof of the dental appliance100. The target marking area may include a laser mark. The laser markmay represent, e.g., appliance and/or patient identificationinformation, decorative marking, brand logos, designs, patient-selectedinformation/decorations, etc.

At an optional operation 229, a laser access area on the dentalappliance that corresponds to a region of the dental appliance thatprovides laser access to the target marking area may be identified. Asnoted herein, the laser access area 106 on the dental appliance 100 maybe identified. The laser access area may be identified on a computersystem either with an automated agent or an individual identifying avirtual representation of the laser access area. The laser access areamay also be identified by a machine or an individual identifying an areaof a dental appliance. The laser access area may comprise a portion ofan interior area or an exterior area of the dental appliance thatresides proximate to the target marking area.

At an operation 231, the target marking area may be formed withinterspersed particulate matter having particulate properties differentthan particulate properties of other portions of the dental appliance.As noted herein, a machine or a human operator may design the targetmarking area to have particulate matter interspersed throughout it. Insome implementations, a machine or human operator may incorporate a mixof materials in an intermediate area of the dental appliance that isbetween interior and exterior areas of the dental appliance. The mix ofmaterials may include particulate matter interspersed with the polymermaterials used for other portions of the dental appliance. The mix ofmaterials may be used to lay out a portion of a thermoformed aligner. Insome implementations, the target marking area may be formed by directfabrication/3D printing techniques. As an example, the target markingarea may be formed layer-by-layer by 3D printing techniques.

FIG. 2D illustrates a flowchart of a method 200D for forming a dentalappliance according to some implementations. The method 200D may includemore or less operations than those explicitly shown in FIG. 2D. Some orall of the operations of the method 200D may be executed by thecomputing system 650 and/or other structures shown in FIG. 6. The method200D may be used for forming the dental appliance 100 shown in FIG. 1.

At an operation 233, a target marking area on a dental appliance formarking the dental appliance with a laser mark may be identified. As anexample, the target marking area 108 on the dental appliance 100 may beidentified. In various implementations, the target marking area isidentified on a computer system either with an automated agent or anindividual identifying a virtual representation of the target markingarea. The target marking area may also be identified by a machine or anindividual identifying an area of a dental appliance. The target markingarea may comprise a portion of an intermediate area, an interior area,an exterior area, or some combination thereof of the dental appliance100. The target marking area may include a laser mark. The laser markmay represent, e.g., appliance and/or patient identificationinformation, decorative marking, brand logos, designs, patient-selectedinformation/decorations, etc.

At an operation 235, a laser access area on the dental appliance thatcorresponds to a region of the dental appliance that provides laseraccess to the target marking area may be identified. As noted herein,the laser access area 106 on the dental appliance 100 may be identified.The laser access area may be identified on a computer system either withan automated agent or an individual identifying a virtual representationof the laser access area. The laser access area may also be identifiedby a machine or an individual identifying an area of a dental appliance.The laser access area may comprise a portion of an interior area or anexterior area of the dental appliance that resides proximate to thetarget marking area.

At an operation 237, the target marking area may be formed. A machine ora human operator may design the target marking area to have particulatematter interspersed throughout it. In some implementations, a machine orhuman operator may incorporate a mix of materials in an intermediatearea of the dental appliance that is between interior and exterior areasof the dental appliance. The mix of materials may include particulatematter interspersed with the polymer materials used for other portionsof the dental appliance. The mix of materials may be used to lay out aportion of a thermoformed aligner. In some implementations, the targetmarking area may be formed by direct fabrication/3D printing techniques.As an example, the target marking area may be formed layer-by-layer by3D printing techniques.

At an operation 239, the laser access area may be formed. The laseraccess area may comprise an area having a surface texture different(e.g., rougher) than the surface texture of other portions of the dentalappliance, such as areas of the dental appliance surrounding and/orproximate to the laser access area. A machine or a human operator mayachieve the different surface texture by abrading, roughing, etc. thesurface of the laser access area relative to other areas of the dentalappliance. A machine or a human operator may achieve the differentsurface texture by including an affirmative manufacturing step to formthe laser access area from a different (e.g., rougher) material thanother areas of the dental appliance so that the laser access area causeslaser energy to disperse through it. Forming the laser access area mayinclude using thermoforming techniques over a physical mold (e.g., a 3Dprinted mold) and/or direct fabricating/3D printing the laser accessarea to have a differing surface texture than other areas of the dentalappliance.

FIG. 3 illustrates another perspective view of a dental appliance 320according to one or more embodiments of the present disclosure. Theappliance 320 can include an appliance body, where at least a portion ofthe appliance body is formed from a transparent (e.g., translucent)material for improved laser marking. In some embodiments, the dentalappliance 320 may be formed from a light transmissive material to allowlight (e.g., a laser beam) from a light source (e.g., a laser) to markthe transparent material of the dental appliance 320. However, in someembodiments, the light used to mark the dental appliance 320 may not bevisible light (e.g., wavelengths between about 390 and 700 nm) and, insuch embodiments, the material may be transparent to the type ofnon-visible light that is being used for marking the dental appliance320.

Laser marking can include directing light from the laser marking sourceto a target area 324 for laser marking of the appliance 320. Theappliance can be transparent to the laser energy from the light allowingthe laser energy to mark the appliance at the target area 324. Thetarget area for laser marking can be defined within the body of theappliance between the interior surface 318 and exterior surface 322. Thetarget area 324 for laser marking can be the laser marking locationwithin the appliance where the laser marking appears which can bebetween the interior and exterior surface including marking on one ofthe surfaces. While FIG. 3 illustrates a single target area, appliancescan include multiple target areas defined within the appliance formultiple laser markings.

The target area 324 within the body of the appliance 320 can contain aquantity of at least one particulate material 326 interspersed withinthe target area 324. For example, the at least one particulate material326 can be interspersed within appliance 320 between the interiorsurface 318 and exterior surface 322 at the target area 324. Particulatematerial 326 can have laser energy absorption characteristics that aregreater than that of the material used to form the body without theparticulate material 326 (e.g., the particulate material 326 has laserenergy absorption characteristics that are greater than that of thematerial forming portions of the body outside of the target area 324).

In some embodiments, the quantity of particulate material 326 can beinterspersed within the materials forming the entire appliance 320. Theappliance 320 is not limited to one type of particulate material 326.For example, more than one particulate material can be interspersedwithin the appliance 320. In various embodiments, the material of thebody can be formed such that the appliance 320 includes a first and asecond target area defined between the interior surface 318 and theexterior surface 322. In such an embodiment, a quantity of firstparticulate material can be interspersed within the first target areaand a quantity of second particulate material can be interspersed withinthe second target area.

Additionally, more than one particulate material can be interspersedwithin a single target area. For example, a first quantity of a firstparticulate material and a second quantity of a second particulatematerial can be interspersed within the target area 324. The firstquantity of the first particulate material and the second quantity ofthe second particulate material can be interspersed within a sameportion of the target area 324 or the first quantity of the firstparticulate material can be interspersed within a portion of the targetarea 324 and the second quantity of the second particulate material canbe interspersed within a portion of the target area 324 that does notcontain the first particulate material.

A particular type of particulate material can have a heightenedreactivity to a particular range of wavelengths of laser energy, whichcan allow for a particular particulate material to be interspersedwithin the material (e.g., a sheet of thermoforming material) used toform the appliance 320 depending on the wavelength of the laser energythat is used for laser marking. For example, a first particulatematerial can have a heightened reactivity to a first range ofwavelengths of laser energy as compared to a second range of wavelength,while a second particulate material can have a heightened reactivity tothe second range of wavelengths of laser energy as compared to the firstrange of wavelengths. In such an embodiment, the first range ofwavelengths of laser energy can be different than the second range ofwavelengths of laser energy.

In such an embodiment, different ranges of wavelengths can correspond toa different shade of black, or a color. Thus, the particulate materialthat is interspersed within the appliance 320 and the range ofwavelengths of laser energy that is used for marking can depend on adesired shade or color of laser marking.

FIGS. 4A-4H illustrate a number of target areas defined within a dentalappliance according to a number of embodiments of the presentdisclosure.

As previously described, multiple target areas can be defined within anappliance between the interior and exterior surfaces. As illustrated inFIGS. 4A-4H, appliances can include more than one target area and/orparticulate materials. The particulate material can have laser energyabsorption characteristics that are greater than that of the transparentmaterial forming portion of the body outside of the target areas.Additionally, in an embodiment where there is more than one particulatematerial, each particular particulate material can have uniquecharacteristics. For instance, each particulate material can have aheightened reactivity to a different particular range of wavelengths oflaser energy of a light from a laser marking source. Thus, a firstparticulate material can have a heightened reactivity to a first rangeof wavelengths of laser energy of a light from a laser marking sourceand the second particulate material can have a heightened reactivity toa second range of wavelengths of laser energy of a light from a lasermarking source, where the first range of wavelengths of laser energy isdifferent than the second range of wavelengths of laser energy.

Each particulate material can also have a unique average particle sizeand/or a particle density. For instance, a first particulate materialcan have a different average particle size and/or particle density thana second particulate material which may cause one particle to react tolaser energy differently than another particle having a differentcharacteristic.

As illustrated in FIG. 4A, appliances can include a first target area444 and a second target area 446 defined within the body between theinterior surface 434 and the exterior surface 436. In such anembodiment, a first quantity of a first particulate material 438 can beinterspersed within the first target area 444 and a second quantity of asecond particulate material 442 can be interspersed within the secondtarget area 446.

As illustrated in FIG. 4B, appliances can include a first target area444 defined within the body between the interior surface 434 and theexterior surface 436. In such an embodiment, a quantity of a firstparticulate material 438 and a quantity of a second particulate material442 can be interspersed within the first target area 444. The quantityof the first particulate material 438 and the quantity of the secondparticulate material 442 can be interspersed within the same portion ofthe first target area 444.

As illustrated in FIG. 4C, appliances can include a first target area444 defined within the body between the interior surface 434 and theexterior surface 436. In such an embodiment, a quantity of a firstparticulate material 438 can be interspersed within the first targetarea 444 and a quantity of a second particulate material 442 can beinterspersed within a portion of the material of the body of theappliance that is outside of the first target area 444.

As illustrated in FIG. 4D, appliances can include a first target area444 defined within the body between the interior surface 434 and theexterior surface 436. In such an embodiment, a quantity of a firstparticulate material 438 can be interspersed within a first portion ofthe first target area 444 and a quantity of a second particulatematerial 442 can be interspersed within second portion of the firsttarget area 444.

In some embodiments, the quantity of the first particulate material 438and the quantity of the second particulate material 442 can beinterspersed within the first target area 444 so that they do notoverlap. Thus, the first portion of the first target area 444 isdifferent than the second portion of the first target area 444.

As illustrated in FIG. 4E, appliances can be formed from multiplelayers. Additionally, the appliance can include a first target area 444defined within the body between the interior surface 434 and theexterior surface 436. In such an embodiment, a quantity of a firstparticulate material 438 can be interspersed within a first portion ofthe first target area 444 and a quantity of a second particulatematerial 442 can be interspersed within second portion of the firsttarget area 444. Additionally, the quantity of the first particulatematerial 438 can be interspersed within a first layer of the applianceand the quantity of the second particulate material 442 can beinterspersed within a second layer of the appliance. Thus, the firstportion of the first target area 444 is different than the secondportion of the first target area 444.

As illustrated in FIG. 4F, appliances formed from multiple layers caninclude a first target area 444 and a second target area 446 definedwithin the body between the interior surface 434 and the exteriorsurface 436. In such an embodiment, a quantity of a first particulatematerial 438 can be interspersed within the first target area 444 and aquantity of a second particulate material 442 can be interspersed withinthe second target area 446. Additionally, the quantity of the firstparticulate material 438 can be interspersed within a first layer of theappliance and the quantity of the second particulate material 442 can beinterspersed within a second layer of the appliance.

As illustrated in FIG. 4G, appliances can include a first target area444 defined within the body between the interior surface 434 and theexterior surface 436. In such an embodiment, a quantity of a firstparticulate material 438 and a quantity of a second particulate material442 can be interspersed together within the first target area 444. Forexample, the quantity of the first particulate material 438 and thequantity of the second particulate material 442 can be mixed togetherand interspersed within the first target area 444, which can allow thefirst and second particulate materials to be activated by more of lessenergy or different wavelength ranges, etc.

As illustrated in FIG. 4H, appliances can include a quantity ofparticulate material interspersed within the body between the interiorsurface 434 and the exterior surface 436. In such an embodiment, thefirst particulate material 438 can have a heightened reactivity to afirst range of wavelengths of laser energy of a light from a lasermarking source. Thus, a laser marking source which supplies light withthe first range of laser energy can laser mark between the interiorsurface 434 and the exterior surface 436, which contains the quantity ofthe first particulate material 438.

FIGS. 5A and 5B illustrate a process for forming a dental applianceaccording to a number of embodiments of the present disclosure. Asillustrated by FIG. 5A, in some embodiments, forming the appliance 554can include thermoforming the appliance from a sheet of material 548placed over a mold 552 of a patient's teeth, for example, based on anarrangement of the teeth determined by a treatment plan. The appliance554 can be formed from a transparent (e.g., translucent) material forimproved laser marking. The sheet of material 548 can also have aninterior and exterior surface, where a particulate material isinterspersed substantially uniformly throughout the entire sheet of thematerial 548 between the interior and exterior surface.

In some embodiments, the dental appliance 554 may be formed from a lighttransmissive material to allow light (e.g., a laser beam) from the lightsource to mark the transparent material of the dental appliance.However, in some embodiments, the light used to mark the dentalappliance may not be visible light and, in such embodiments, thematerial may be transparent to the type of non-visible light that isbeing used for marking the dental appliance (e.g., ultraviolet (UV)light).

Thermoforming the appliance from the sheet of material 548 placed overthe mold 552 of the patient's teeth can include heating the sheet andthen vacuum or pressure forming the sheet over the mold 552 of thepatient's teeth. The appliance is then a direct representation of themold 552 of the patient's teeth. Excess material can be trimmed to forma final appliance 554 that can be used for orthodontic treatment of thepatient. Alternatively, in some embodiments, the appliance can be formedby three dimensional printing rather than from a sheet of material.

As illustrated in FIG. 5B, the appliance 554 can be formed from atransparent material for improved laser marking. As previouslydescribed, the appliance 554 can include an exterior surface at a laseraccess area that has a textured (e.g., rougher) surface than at least aportion of the interior surface. The surface texture of a laser accessarea may interact with laser energy from light 558 from a laser markingsource 562 to disperse the laser energy at the target area for lasermarking defined within the appliance 554.

Additionally, the target area can contain a quantity of particulatematerial interspersed within the target area. The particulate materialmay have laser radiation absorption characteristics that are greaterthan that of the transparent material that is used to form the appliance554 (e.g., the material used to form the sheet that is not theparticulate material) allowing the laser energy from the light to befully absorbed by the particulate material. The laser radiationabsorption characteristics may allow for marking contrast, line edgeddetail, and increased marking speed on plastic materials that have beentraditionally difficult to achieve resulting in increased laser markreading and creation efficiency.

Thus, the laser marking source 562 can direct light 558 at the laseraccess area and the rougher surface texture of the laser access area canbe configured to disperse the laser energy from the light 558 for lasermarking as the laser energy interacts with the rougher surface texture.In this manner, the particulate material interspersed within the targetarea can absorb the laser energy to create a laser marking 556. Thelaser marking 556 can include an object imprinted into the material ofthe appliance, such as appliance and/or patient identificationinformation. Disbursing the laser energy can promote heating of thematerial imprinting (e.g., marking) the object into the appliance 554.The laser marking 556 (e.g., the imprinted object) can be colored or inblack.

FIG. 6 illustrates a computing system 650 for use in a number ofembodiments of the present disclosure. FIG. 6 illustrates a computingsystem 650 for use in a number of embodiments of the present disclosure.For instance, a computing device 665 can have a number of componentscoupled thereto. The computing device 665 can include a processor 688and a memory 666. The memory 666 can have various types of informationincluding data 672 and executable instructions 668, as discussed herein.

The processor 688 can execute instructions 668 that are stored on aninternal or external non-transitory computer device readable medium(CRM). A non-transitory CRM, as used herein, can include volatile and/ornon-volatile memory.

Volatile memory can include memory that depends upon power to storeinformation, such as various types of dynamic random access memory(DRAM), among others. Non-volatile memory can include memory that doesnot depend upon power to store information.

Memory 666 and/or the processor 688 may be located on the computingdevice 665 or off of the computing device 665, in some embodiments. Assuch, as illustrated in the embodiment of FIG. 6, the computing device665 can include a network interface 664. Such an interface 664 can allowfor processing on another networked computing device, can be used toobtain information about the patient (e.g., characteristics of thepatient's mouth and/or treatment planning information) and/or can beused to obtain data and/or executable instructions for use with variousembodiments provided herein.

In some embodiments, a computing device can be used to design the sheetwith interspersed particulate (e.g., selecting the type of particulate,where the particulate is to be positioned within the sheet, design of alayered sheet, etc.) or select materials for three dimensional printing.Computing devices can also be used to design patterns to be used torough a surface of an appliance and/or tools to accomplish suchroughing.

As illustrated in the embodiment of FIG. 6, the computing device 665 caninclude one or more input and/or output interfaces 674. Such interfaces674 can be used to connect the computing device 665 with one or moreinput and/or output devices 676, 678, 682, 684, 686.

For example, in the embodiment illustrated in FIG. 6, the input and/oroutput devices can include a scanning device 676, a camera dock 678, aninput device 682 (e.g., a mouse, a keyboard, etc.), a display device 684(e.g., a monitor), a printer 686, and/or one or more other inputdevices. The input/output interfaces 674 can receive executableinstructions and/or data, storable in the data storage device (e.g.,memory 666), representing a virtual dental model of a patient'sdentition.

In some embodiments, the scanning device 676 can be configured to scanone or more physical dental molds of a patient's dentition. In one ormore embodiments, the scanning device 676 can be configured to scan thepatient's dentition, a dental appliance, and/or an attachment directly.The scanning device 676 can be configured to input data into thecomputing device 665 which can then be used for treatment planningand/or generating digital 3D models of the patient's dentition. Thisinformation can also be used to estimate the forces discussed herein.

In some embodiments, the camera dock 678 can receive an input from animaging device (e.g., a 2D or 3D imaging device) such as a digitalcamera, a printed photograph scanner, and/or other suitable imagingdevice. The input from the imaging device can, for example, be stored inmemory 666.

The processor 688 can execute instructions to provide a visualindication of a treatment plan, a dental appliance, one or more targetareas, and/or one or more laser access areas on the display 684. Thecomputing device 665 can be configured to allow a treatment professionalor other user to input treatment goals. Input received can be sent tothe processor 688 as data 672 and/or can be stored in memory 666.

The data 672 may include a 3D model of an object to be 3D printed by theprinter 686. The 3D model may comprise a mathematical representation ofone or more surfaces of the object. The 3D model may have been renderedthrough automated agents or by an operator through, e.g., the techniquesdiscussed further herein. The 3D model may be stored as a digital modelfile of a 3D virtual representation of a 3D object to be printed. Thedigital model file may be formatted according to a variety of formats,such as an Additive Manufacturing File (AMF) (e.g., one that usessequential layers), an STL file, a fused deposit modeling (FDM) file,etc.

Such connectivity can allow for the input and/or output of data and/orinstructions among other types of information. Some embodiments may bedistributed among various computing devices within one or more networks,and such systems as illustrated in FIG. 6 can be beneficial in allowingfor the capture, calculation, and/or analysis of information discussedherein.

The processor 688, can be in communication with the data storage device(e.g., memory 666), which has the data 672 stored therein. The processor688, in association with the memory 666, can store and/or utilize data672 and/or execute instructions 668 for forming an appliance forimproved laser marking.

The processor 688, in association with the memory 666 can, in additionto or alternatively, store and/or utilize data 672 and/or executeinstructions 668 for creating a dental appliance for improved lasermarking, as well as a virtual modeling of such an item. The processor688 coupled to the memory 666 can, for example, include instructions tocause the computing device 665 to perform a method including, forexample, forming a virtual dental appliance body indicated as beingformed from at least one material, at least a portion of the bodyindicated as being transparent to laser energy, and defining in thevirtual body, a virtual target area for laser marking between aninterior surface and an exterior surface of the appliance body andincluding interspersing a virtual first particulate material within thetarget area, where the first particulate material indicated as having aheightened reactivity to a first range of wavelengths of laser energy ascompared to a second range of wavelengths.

In various embodiments, the processor 688 coupled to the memory 666 cancause the computing device 665 to perform the method comprising forminga virtual dental appliance body indicated as being formed from at leastone material, at least a portion of the body indicated as beingtransparent to laser energy, and defining in the virtual body, a virtualtarget area for laser marking between an interior surface and anexterior surface of the appliance body, defining a virtual laser accessarea on at least one of the virtual interior or exterior surfaces, anddefining a roughed portion on at least a portion of the virtual laseraccess area such that the roughed portion has a rougher surface texturethan at least one of, a portion of the virtual exterior surface that isnot within the laser access area or a portion of the virtual interiorsurface.

Such analysis can be accomplished one or more times for a treatmentplan. For example, if a treatment plan has 30 stages, it would bepossible to have different dental appliance configurations for eachstage or possibly more, if desired. However, in many instances thedental appliance shape, position, and/or orientation may be changed afew times during the treatment plan.

The executable instructions 668 may comprise instructions to transform a3D model of an object into printable portions that can be printed by theprinter 686. In some implementations, the executable instructions 668may comprise instructions to “slice” a 3D model, e.g., to convert the 3Dmodel into a set of thin layers that are to be 3D printed by the printer686. In some implementations, the executable instructions 668 convert a3D model into a sliced format file (e.g., a G-code file) that can beprovided to the printer 686.

In some implementations, the display 684 may be configured to display a2D rendering of a 3D model of an object to be 3D printed. The 2Drendering may have been developed through simulations, projections,mappings, etc. of the 3D model into a 2D space. The display 684 mayfurther be configured to display user interface elements to allow anoperator to interact with a 3D model.

In some embodiments, the printer 686 can be a three-dimensional ordirect fabrication device that can create a dental appliance directlyfrom instructions from the computing device 665. Embodiments of thepresent disclosure utilizing such technology can be particularlybeneficial for a variety of reasons. For example, such directmanufacture allows for less waste of materials due to less processingsteps.

The printer 686 may be configured to use additive manufacturingtechniques to print 3D objects using virtual representations of those 3Dobjects. In some implementations, the printer 686 join and/or solidifymaterial (e.g., polymeric material) based on instructions from theprocessor 688 to create a 3D object. As noted herein, the printer 686may receive from the memory 666 a sliced format file. The printer 686may successively add material to a 3D object on a layer-by-layer basisusing, e.g., SLA, FDM, etc.

The printer 686 may print a 3D object at a specified resolution. Theresolution of the printer 686 may describe layer thickness(es) and/orX-Y resolutions in a convenient format, such as dots per inch (dpi) ormicrometers (μm).

FIG. 7 illustrates a memory 766 for use in a number of embodiments ofthe present disclosure. Memory 766 may be, for example, memory 666previously described in connection with FIG. 6.

The memory 766 may have various types of information includingexecutable instructions 768 and data 772, as discussed herein.Additionally, the memory 766 may include one or more engines anddatastores. A computer system can be implemented as an engine, as partof an engine or through multiple engines. As used herein, an engineincludes one or more processors or a portion thereof. A portion of oneor more processors can include some portion of hardware less than all ofthe hardware comprising any given one or more processors, such as asubset of registers, the portion of the processor dedicated to one ormore threads of a multi-threaded processor, a time slice during whichthe processor is wholly or partially dedicated to carrying out part ofthe engine's functionality, or the like.

As such, a first engine and a second engine can have one or morededicated processors or a first engine and a second engine can share oneor more processors with one another or other engines. Depending uponimplementation-specific or other considerations, an engine can becentralized or its functionality distributed. An engine can includehardware, firmware, or software embodied in a computer-readable mediumfor execution by the processor. The processor transforms data into newdata using implemented data structures and methods, such as is describedwith reference to the FIGS. herein.

The engines described herein, or the engines through which the systemsand devices described herein can be implemented, can be cloud-basedengines. As used herein, a cloud-based engine is an engine that can runapplications and/or functionalities using a cloud-based computingsystem. All or portions of the applications and/or functionalities canbe distributed across multiple computing devices and need not berestricted to only one computing device. In some embodiments, thecloud-based engines can execute functionalities and/or modules that endusers access through a web browser or container application withouthaving the functionalities and/or modules installed locally on theend-users' computing devices.

As used herein, datastores are intended to include repositories havingany applicable organization of data, including tables, comma-separatedvalues (CSV) files, traditional databases (e.g., SQL), or otherapplicable known or convenient organizational formats. Datastores can beimplemented, for example, as software embodied in a physicalcomputer-readable medium on a specific-purpose machine, in firmware, inhardware, in a combination thereof, or in an applicable known orconvenient device or system. Datastore-associated components, such asdatabase interfaces, can be considered “part of” a datastore, part ofsome other system component, or a combination thereof, though thephysical location and other characteristics of datastore-associatedcomponents is not critical for an understanding of the techniquesdescribed herein.

Datastores can include data structures. As used herein, a data structureis associated with a particular way of storing and organizing data in acomputer so that it can be used efficiently within a given context. Datastructures are generally based on the ability of a computer to fetch andstore data at any place in its memory, specified by an address, a bitstring that can be itself stored in memory and manipulated by theprogram. Thus, some data structures are based on computing the addressesof data items with arithmetic operations; while other data structuresare based on storing addresses of data items within the structureitself. Many data structures use both principles, sometimes combined innon-trivial ways. The implementation of a data structure usually entailswriting a set of procedures that create and manipulate instances of thatstructure. The datastores, described herein, can be cloud-baseddatastores. A cloud based datastore is a datastore that is compatiblewith cloud-based computing systems and engines.

The virtual tooth representation management engine 790 may include oneor more automated agents configured to gather virtual representations ofteeth of a patient from the virtual tooth representation datastore 7102.The virtual tooth representation management engine 790 may provide anidentifier of a patient and retrieve from the virtual toothrepresentation datastore 7102 virtual representations of teeth of thepatient.

In various implementations, the virtual tooth representation managementengine 790 renders a 3D virtual representation of teeth for display on acomputer display. As an example, the virtual tooth representationmanagement engine 790 may load 3D graphics corresponding to variousperspectives (sagittal, median, frontal/coronal, transverse/axial etc.perspectives) of a patient's teeth.

The optional force system analysis engine 792 may include one or moreautomated agents configured to gather an orthodontic treatment plan fromthe optional treatment plan datastore 7104. In some implementations, theoptional force system analysis engine 792 is configured to gather froman orthodontic treatment plan a set of positional force systems to applyto a patient's teeth.

The positional force systems may include linear forces, torques, anchorforces, etc. that are to be applied to the patient's teeth over thecourse of the orthodontic treatment plan. The positional force systemsmay be implemented by aligners, attachments, or some combinationthereof.

The 3D surface export engine 796 may include one or more automatedagents configured to export a 3D surface model. The 3D surface exportengine 796 may save a 3D surface model in a relevant format, configure a3D surface model for streaming, and/or format a 3D surface model for 3Dprinting, for instance.

The virtual tooth representation datastore 7102 may be configured tostore virtual representations of teeth. The virtual tooth representationdatastore 7102 may index the virtual representations of teeth by patientand/or by stage of a treatment plan. As noted further herein, thevirtual representations of teeth may comprise position(s),orientation(s), etc. of teeth of a patient that is relevant toapplication of orthodontic aligners to the patient. In someimplementations, the virtual representations of teeth areestimates/approximations of a patient's teeth at a beginning, end, orintermediate stage of an orthodontic treatment plan. In someimplementations, virtual representations of teeth are stored as virtualobjects that can be accessed by the engines described herein.

The optional treatment plan datastore 7104 may be configured to storetreatment plan data. The treatment plan data may include instructions toapply aligners and/or attachments to teeth to generate variousorthodontic outcomes. The treatment plan data may, for instance, includeinstructions to apply force positioning systems to teeth at differenttimes in order to achieve translations, rotations, anchors, etc. tothose teeth.

The virtual laser marking datastore 7106 may be configured to storevirtual representations of laser markings. The virtual representationsof laser markings may include size parameters, shape parameters, and/ororientation parameters, as well as roughing or particulate parametersrelated to how the marking is to be accomplished. In someimplementations, virtual representations of laser markings are stored asvirtual objects that can be accessed by the engines described herein.

FIG. 8 illustrates a non-transitory computer readable medium 870 havinginstructions for forming a dental appliance according to a number ofembodiments of the present disclosure.

Instructions 894 can include forming a virtual dental appliance bodyindicated as being formed from at least one material, at least oneportion of the body indicated as being transparent to laser energy, anddefining in the virtual body, a virtual target area for laser markingbetween an interior surface and an exterior surface of the appliancebody.

Instructions 896 can include defining a virtual laser access area on atleast one of the virtual interior or exterior surfaces. The virtuallaser access area can be configured to disperse light energy from lightfrom a laser marking source at the virtual target area within theappliance.

Instructions 898 can include defining a roughed portion on at least aportion of the virtual laser access area such that the roughed portionhas a rougher surface texture than at least one of, a portion of thevirtual exterior surface that is not within the laser access area or aportion of the virtual interior surface. The rougher surface texture canbe provided by a non-random pattern of surface features formed in thevirtual exterior surface or interior surface.

The non-random pattern of surface features can be configured to disperselaser energy at the target area in a manner based on the laser energy'sinteraction with the non-random pattern. In another embodiment, therougher surface area can be provided by a random pattern of surfacefeatures formed in the exterior surface or the interior surface. Therandom pattern of surface features can be configured to disperse laserenergy at the target area in a manner based on the laser energy'sinteraction with the random pattern.

Surface features formed in the virtual exterior or interior surfaces ofthe virtual appliance can include height variations, translucencyvariations, and density variations, among other surface features. Thesurface features can be configured to promote heating in one or moreparticular areas of the virtual target area when the laser energy isapplied to the virtual appliance by the laser marking source.

Instructions can further include creating a physical dental appliancebased on the virtual dental appliance body having the physical laseraccess area with a roughed portion and target area. The virtual modelcan be provided to a fabrication device for fabrication of a physicalmodel corresponding to the jaw for formation of the appliance. Thevirtual model can be provided (e.g., via network interface) to afabrication device for fabrication of physical models corresponding tothe jaw at the first and the second stages of the treatment plan forformation of appliances thereover such that the appliance having thephysical laser access area with a roughed portion and target area.

FIG. 9 illustrates a non-transitory computer readable medium 980 havinginstructions for forming a dental appliance according to a number ofembodiments of the present disclosure.

Instructions 9104 can include forming a virtual dental appliance bodyindicated as being formed from at least one material, at least a portionof the body transparent to laser energy. In the virtual body, a virtualtarget area for laser marking can be defined between an interior surfaceand an exterior surface of the appliance body. Additionally, a virtualfirst particulate material can be interspersed within the target area,where the virtual first particulate material can be indicated to have aheightened reactivity to a first range of wavelengths of laser energycompared to a second range of wavelengths.

Further, instructions can include forming a physical dental appliancebody from the indicated at least one material, where at least a portionof the body is transparent to laser energy (e.g., at least translucentto the laser energy used for marking). Additionally, defining in thebody, a target area for laser marking between an interior and anexterior surface of the appliance body. The target area can include afirst particulate material interspersed within the target area, wherethe first particulate material has a heightened reactivity to a firstrange of wavelengths of laser energy as compared to a second range ofwavelengths.

FIG. 10A illustrates a flowchart of a method 1000A for providing a lasermark through a laser access area of a dental appliance, according tosome implementations. The method 1000A may include more or lessoperations than those explicitly shown in FIG. 10A. Some or all of theoperations of the method 1000A may be executed by the computing system650 and/or other structures shown in FIG. 6. The method 1000A may beused to mark the dental appliance 100 shown in FIG. 1 with a laser markthrough the laser access area 106.

At an operation 1003, a target marking area on a dental appliance formarking the dental appliance with a laser mark may be identified. At anoperation 1005, laser access area with first surface texture differentthan second surface texture of other portion of the dental appliance maybe identified. The laser access area may provide laser access to thetarget marking area. At an operation 1007, laser energy may be providedthrough the laser access area to disperse the laser energy through thelaser access area. At an operation 1009, the laser energy may be used toput a laser mark on the target marking area through the laser accessarea.

FIG. 10B illustrates a flowchart of a method 1000B for providing a lasermark to a target marking area of a dental appliance, according to someimplementations. The method 1000B may include more or less operationsthan those explicitly shown in FIG. 10B. Some or all of the operationsof the method 1000B may be executed by the computing system 650 and/orother structures shown in FIG. 6. The method 1000B may be used to markthe dental appliance 100 shown in FIG. 1 with a laser mark at the targetmarking area 108.

At an operation 1011, a target marking area with interspersedparticulate matter on a dental appliance for marking the dentalappliance with a laser mark may be identified. At an operation 1013,laser access area of the dental appliance aligner may be identified. Thelaser access area may provide laser access to the target marking area.At an operation 1015, laser energy may be provided through the laseraccess area. At an operation 1017, the laser energy may be received atthe interspersed particulate matter to put a laser mark on the targetmarking area through the laser access area.

The dental appliances described herein may include one or more polymermaterials, including one or more polyester, copolyester, polycarbonate,copolycarbonate, and polyurethane materials. FIGS. 11-13 illustrate testresults comparing laser markings on substrates made of various polymermaterials and having different surface textures. In each of the tests, aROFIN E25 Air laser (e.g., Coherent, Inc., Santa Clara, Calif.) was usedto make the laser markings. As shown in each of the examples of FIGS.11-13, the laser markings on the textured (e.g., matte or roughened)surfaces are darker than the laser markings on the un-textured orless-textured (e.g., glossy or smoother) surfaces. These examplesillustrate how surface textures having a greater roughness can influencethe laser marking process and result in higher contrast markings thatare easier to detect optically compared to surfaces having lowerroughness.

FIG. 11 illustrates a comparison of laser markings made on un-textured1103 (e.g., glossy) and textured 1105 (e.g., matte) surfaces of a testsubstrate made of Tritan™ 30 (Eastman Chemical Company). A laser speedof 700 mm/s, laser power of 30 A, and frequency of 19 KHz were used. Thetextured (matte) surface portion of the substrate was measured to have asurface roughness Ra of 12.97 micrometers per inch and Rz of 102.96micrometers per inch. The glossy surface portion of the substrate wasmeasured to have a surface roughness Ra of 0.51 micrometers per inch andRz of 12.23 micrometers per inch. As shown the laser marking on thetextured surface 1109 was more visible than the laser mark on theun-textured surface 1107, when the same laser power was used in the samematerial.

FIG. 12 illustrates a comparison of laser markings made on un-textured1203 (e.g., glossy) and textured 1205 (e.g., matte) surfaces of a testsubstrate made of ST 30 material. A laser speeds of 500 mm/s, 600 mm/s,700 mm/s, 800 mm/s, and 900 mm/s; laser powers of 30 A, 32 A, 34 A, and36 A; and frequency of 19 KHz were used. The matte surface portion ofthe substrate was measured to have a surface roughness Ra of 9.96micrometers per inch and Rz of 52.55 micrometers per inch. The glossysurface portion of the substrate was measured to have a surfaceroughness Ra of 0.65 micrometers per inch and Rz of 4.95 micrometers perinch. The texture surface portion 1305 resulted in substantially darkermarkings as compared to markings 1307 on the un-textured surface usingthe same laser settings.

FIG. 13 illustrates a comparison of laser markings made on un-textured1303 (e.g., glossy) and textured 1305 (e.g., matte) surfaces of a testsubstrate made of EX 40 material. A laser speeds of 500 mm/s, 600 mm/s,700 mm/s, and 800 mm/s; laser powers of 30 A, 32 A, 34 A, and 36 A; andfrequency of 19 KHz were used. The textured surface portion of thesubstrate was measured to have a surface roughness Ra of 29.97micrometers per inch and Rz of 182.74 micrometers per inch and resultedin significantly darker markings 1307 as compared to the un-texturedmarkings 1309 made with the same laser settings. The un-textured (e.g.,glossy) surface portion of the substrate was measured to have a surfaceroughness Ra of 1.10 micrometers per inch and Rz of 22.04 micrometersper inch.

Reference herein is made to the accompanying drawings that form a parthereof, and in which is shown by way of illustration how a number ofembodiments of the disclosure may be practiced. These embodiments aredescribed in sufficient detail to enable those of ordinary skill in theart to practice the embodiments of this disclosure, and it is to beunderstood that other embodiments may be utilized and that processand/or structural changes may be made without departing from the scopeof the present disclosure. As used herein, “a number of” a particularthing can refer to one or more of such things (e.g., a number of biteadjustment structures can refer to one or more bite adjustmentstructures).

The figures herein follow a numbering convention in which the firstdigit or digits correspond to the drawing figure number and theremaining digits identify an element or component in the drawing.Similar elements or components between different figures may beidentified by the use of similar digits. For example, 106 may referenceelement “06” in FIG. 1, and a similar element may be referenced as 606in FIG. 6.

As will be appreciated, elements shown in the various embodiments hereincan be added, exchanged, and/or eliminated so as to provide a number ofadditional embodiments of the present disclosure. In addition, as willbe appreciated, the proportion and the relative scale of the elementsprovided in the figures are intended to illustrate certain embodimentsof the present invention, and should not be taken in a limiting sense.

The embodiments of the present disclosure provide mechanisms forimproving marking readability, allowing for expanded markingcapabilities, and more efficient marking processes. Although discussedherein with respect to marking of dental appliances, such techniquescould be beneficial in many industries where laser marking is utilized.

Although specific embodiments have been illustrated and describedherein, those of ordinary skill in the art will appreciate that anyarrangement calculated to achieve the same techniques can be substitutedfor the specific embodiments shown. This disclosure is intended to coverany and all adaptations or variations of various embodiments of thedisclosure.

Any of the methods (including user interfaces) described herein may beimplemented as software, hardware or firmware, and may be described as anon-transitory computer-readable storage medium storing a set ofinstructions capable of being executed by a processor (e.g., computer,tablet, smartphone, etc.), that when executed by the processor causesthe processor to control perform any of the steps, including but notlimited to: displaying, communicating with the user, analyzing,modifying parameters (including timing, frequency, intensity, etc.),determining, alerting, or the like.

When a feature or element is herein referred to as being “on” anotherfeature or element, it can be directly on the other feature or elementor intervening features and/or elements may also be present. Incontrast, when a feature or element is referred to as being “directlyon” another feature or element, there are no intervening features orelements present. It will also be understood that, when a feature orelement is referred to as being “connected”, “attached” or “coupled” toanother feature or element, it can be directly connected, attached orcoupled to the other feature or element or intervening features orelements may be present. In contrast, when a feature or element isreferred to as being “directly connected”, “directly attached” or“directly coupled” to another feature or element, there are nointervening features or elements present. Although described or shownwith respect to one embodiment, the features and elements so describedor shown can apply to other embodiments. It will also be appreciated bythose of skill in the art that references to a structure or feature thatis disposed “adjacent” another feature may have portions that overlap orunderlie the adjacent feature.

Terminology used herein is for the purpose of describing particularembodiments only and is not intended to be limiting of the invention.For example, as used herein, the singular forms “a”, “an” and “the” areintended to include the plural forms as well, unless the context clearlyindicates otherwise. It will be further understood that the terms“comprises” and/or “comprising,” when used in this specification,specify the presence of stated features, steps, operations, elements,and/or components, but do not preclude the presence or addition of oneor more other features, steps, operations, elements, components, and/orgroups thereof. As used herein, the term “and/or” includes any and allcombinations of one or more of the associated listed items and may beabbreviated as “/”.

Spatially relative terms, such as “under”, “below”, “lower”, “over”,“upper” and the like, may be used herein for ease of description todescribe one element or feature's relationship to another element(s) orfeature(s) as illustrated in the Figures. It will be understood that thespatially relative terms are intended to encompass differentorientations of the device in use or operation in addition to theorientation depicted in the Figures. For example, if a device in theFIGS. is inverted, elements described as “under” or “beneath” otherelements or features would then be oriented “over” the other elements orfeatures. Thus, the exemplary term “under” can encompass both anorientation of over and under. The device may be otherwise oriented(rotated 90 degrees or at other orientations) and the spatially relativedescriptors used herein interpreted accordingly. Similarly, the terms“upwardly”, “downwardly”, “vertical”, “horizontal” and the like are usedherein for the purpose of explanation only unless specifically indicatedotherwise.

Although the terms “first” and “second” may be used herein to describevarious features/elements (including steps), these features/elementsshould not be limited by these terms, unless the context indicatesotherwise. These terms may be used to distinguish one feature/elementfrom another feature/element. Thus, a first feature/element discussedbelow could be termed a second feature/element, and similarly, a secondfeature/element discussed below could be termed a first feature/elementwithout departing from the teachings of the present invention.

Throughout this specification and the claims which follow, unless thecontext requires otherwise, the word “comprise”, and variations such as“comprises” and “comprising” means various components can be co-jointlyemployed in the methods and articles (e.g., compositions and apparatusesincluding device and methods). For example, the term “comprising” willbe understood to imply the inclusion of any stated elements or steps butnot the exclusion of any other elements or steps.

In general, any of the apparatuses and methods described herein shouldbe understood to be inclusive, but all or a sub-set of the componentsand/or steps may alternatively be exclusive, and may be expressed as“consisting of” or alternatively “consisting essentially of” the variouscomponents, steps, sub-components or sub-steps.

As used herein in the specification and claims, including as used in theexamples and unless otherwise expressly specified, all numbers may beread as if prefaced by the word “about” or “approximately,” even if theterm does not expressly appear. The phrase “about” or “approximately”may be used when describing magnitude and/or position to indicate thatthe value and/or position described is within a reasonable expectedrange of values and/or positions. For example, a numeric value may havea value that is +/−0.1% of the stated value (or range of values), +/−1%of the stated value (or range of values), +/−2% of the stated value (orrange of values), +/−5% of the stated value (or range of values), +/−10%of the stated value (or range of values), etc. Any numerical valuesgiven herein should also be understood to include about or approximatelythat value, unless the context indicates otherwise. For example, if thevalue “10” is disclosed, then “about 10” is also disclosed. Anynumerical range recited herein is intended to include all sub-rangessubsumed therein. It is also understood that when a value is disclosedthat “less than or equal to” the value, “greater than or equal to thevalue” and possible ranges between values are also disclosed, asappropriately understood by the skilled artisan. For example, if thevalue “X” is disclosed the “less than or equal to X” as well as “greaterthan or equal to X” (e.g., where X is a numerical value) is alsodisclosed. It is also understood that the throughout the application,data is provided in a number of different formats, and that this data,represents endpoints and starting points, and ranges for any combinationof the data points. For example, if a particular data point “10” and aparticular data point “15” are disclosed, it is understood that greaterthan, greater than or equal to, less than, less than or equal to, andequal to 10 and 15 are considered disclosed as well as between 10 and15. It is also understood that each unit between two particular unitsare also disclosed. For example, if 10 and 15 are disclosed, then 11,12, 13, and 14 are also disclosed.

Although various illustrative embodiments are described above, any of anumber of changes may be made to various embodiments without departingfrom the scope of the invention as described by the claims. For example,the order in which various described method steps are performed mayoften be changed in alternative embodiments, and in other alternativeembodiments one or more method steps may be skipped altogether. Optionalfeatures of various device and system embodiments may be included insome embodiments and not in others. Therefore, the foregoing descriptionis provided primarily for exemplary purposes and should not beinterpreted to limit the scope of the invention as it is set forth inthe claims.

The examples and illustrations included herein show, by way ofillustration and not of limitation, specific embodiments in which thesubject matter may be practiced. As mentioned, other embodiments may beutilized and derived there from, such that structural and logicalsubstitutions and changes may be made without departing from the scopeof this disclosure. Such embodiments of the inventive subject matter maybe referred to herein individually or collectively by the term“invention” merely for convenience and without intending to voluntarilylimit the scope of this application to any single invention or inventiveconcept, if more than one is, in fact, disclosed. Thus, althoughspecific embodiments have been illustrated and described herein, anyarrangement calculated to achieve the same purpose may be substitutedfor the specific embodiments shown. This disclosure is intended to coverany and all adaptations or variations of various embodiments.Combinations of the above embodiments, and other embodiments notspecifically described herein, will be apparent to those of skill in theart upon reviewing the above description.

1-45. (canceled)
 46. A dental appliance, comprising: an appliance bodyformed from at least one material and at least a portion of the bodybeing transparent to laser energy, wherein; the body having an interiorsurface to contact surfaces of the one or more teeth and an exteriorsurface, and a first target area for laser marking within the bodybetween the interior and exterior surfaces; and the first target areawithin the body contains a quantity of at least one particulate materialinterspersed within the first target area, the at least one particulatematerial having laser energy absorption characteristics that are greaterthan that of the material used to form the body without the at least oneparticulate material.
 47. The dental appliance of claim 46, wherein theparticulate material comprises a pigment or dye.
 48. The dentalappliance of claim 46, wherein a quantity of first particulate materialis interspersed within the materials forming the entire body.
 49. Thedental appliance of claim 46, wherein the material of the body is formedsuch that a second target area for laser marking is defined within thebody between the interior and exterior surfaces, and wherein the secondtarget area within the body contains a quantity of second particulatematerial interspersed within the second target area.
 50. The dentalappliance of claim 46, wherein the body is formed from multiple layersand wherein the first target area is within a first layer and whereinmaterial of the body is formed such that a second target area for lasermarking is defined within a second layer of the body between theinterior and exterior surfaces, and wherein the second target areawithin the body contains a quantity of second particulate materialinterspersed within the second target area.
 51. The dental appliance ofclaim 46, wherein the first target area within the body contains aquantity of a second particulate material interspersed within the firsttarget area.
 52. The dental appliance of claim 51, wherein the firstparticulate material has a heightened reactivity to a first range ofwavelengths of laser energy as compared to a second range ofwavelengths.
 53. The dental appliance of claim 51, wherein the secondparticulate material has a heightened reactivity to a second range ofwavelengths of laser energy that is a different range of wavelengthsthan the first range of wavelengths.
 54. A dental appliance, comprising:an appliance body formed from at least one material wherein at least aportion of the body is transparent to laser energy, wherein; an interiorsurface on the appliance body configured to contact surfaces of the oneor more teeth and an exterior surface, and a first target area of theappliance body for laser marking within the body between the interiorand exterior surfaces; and a means for increasing one or more laserenergy absorption characteristics that are present in the at least onematerial that is transparent to laser energy.
 55. A dental appliancecomprising: an exterior surface formed from a first polymeric material,the first polymeric material having a first laser absorptioncharacteristic, the exterior surface configured to interface with buccaland lingual regions of a patient; an interior surface formed from thefirst polymeric material, the interior surface including a plurality oftooth-receiving cavities to receive a corresponding plurality of teethand to exert one or more orthodontic repositioning forces on theplurality of teeth; an intermediate area residing between the exteriorsurface and the interior surface, the intermediate area including atarget marking area formed from a second polymeric material comprisinginterspersed particulate matter interspersed with the first polymericmaterial, the second polymeric material having a second laser absorptioncharacteristic greater than the first laser absorption characteristic.56. The dental appliance of claim 55, wherein the dental appliance isone of a series of removable polymeric orthodontic appliances.
 57. Thedental appliance of claim 55, wherein the interspersed particulatematter comprises one or more of an additive, a filler, a pigment, and adye.
 58. A dental appliance, comprising: an appliance body, at least aportion thereof being transparent to laser energy used by a laser thatdirects laser energy at the appliance body to conduct laser marking andthe body having a plurality of cavities therein designed to receive oneor more teeth of a jaw of a patient and the plurality of cavitiesproviding force to reposition at least one tooth of the jaw with respectto at least one other tooth of the jaw, wherein; the body has aninterior surface to contact surfaces of the one or more teeth and anexterior surface; and the body is formed such that a first target areafor laser marking is defined within the body between the interior andexterior surfaces; and the first target area within the body contains afirst quantity of a first particulate material interspersed within thefirst target area, the first particulate material having laser energyabsorption characteristics that are greater than that of materialforming portions of the body outside of the first target area.
 59. Thedental appliance of claim 58, wherein the first quantity of firstparticulate material is interspersed within the first target area and asecond quantity of the at least one particulate material is interspersedin a portion of the material of the body that is outside the firsttarget area.
 60. The dental appliance of claim 58, wherein the firstquantity of first particulate material is interspersed within a firstportion of the first target area and a second quantity of the at leastone particulate material is interspersed in a second portion of thefirst target area.
 61. The dental appliance of claim 60, furtherincluding a second quantity of the at least one particulate material isinterspersed in a portion of the material of the body that defines asecond target area.
 62. The dental appliance of claim 58, wherein thefirst target area within the body contains a quantity of a secondparticulate material interspersed within the first target area.
 63. Thedental appliance of claim 62, wherein the second particulate materialhas a different average particle size than the first particulatematerial.
 64. The dental appliance of claim 61, wherein the secondparticulate material has a different average particle density as it isdispersed throughout the body than the first particulate material.
 65. Amethod comprising: identifying an exterior surface of a dentalappliance, the exterior surface configured to interface with buccal andlingual regions of a patient; identifying an interior surface of thedental appliance, the interior surface including a plurality oftooth-receiving cavities to receive a corresponding plurality of teethand to exert one or more orthodontic repositioning forces on theplurality of teeth; identifying a target marking area on the dentalappliance, the target marking area residing in an intermediate arearesiding between the exterior surface and the interior surface; formingthe interior surface and the exterior surface from a first polymericmaterial, the first polymeric material having a first laser absorptioncharacteristic; forming the laser access area from a second polymericmaterial comprising interspersed particulate matter interspersed withthe first polymeric material, the second polymeric material having asecond laser absorption characteristic greater than the first laserabsorption characteristic.